Stage Documents Requirements

Define project scope, objectives, and quality objectives, as per IATF 16949 clause
Product Quality Plan (PQP)
6.1.1.1
Identify customer requirements, including special characteristics, and relevant
Project Plan
regulatory requirements (IATF 16949 clause 4.3.1.1, 7.2.1)
Develop a comprehensive process flow diagram to illustrate the sequence of
1. Planning Process Flow Diagram (PFD)
operations and interactions (IATF 16949 clause 8.3.1)
Develop control plans outlining key characteristics, measurement methods,
Control Plan
sampling plans, and reaction plans (IATF 16949 clause 8.5.1)
Failure Modes and Effects Conduct PFMEA to identify potential failure modes, their effects, and actions to
Analysis (FMEA) mitigate risks (IATF 16949 clause 8.4.1)
Complete DFMEA to analyze potential failure modes related to product design (IATF
Design FMEA
16949 clause 8.4.2)
Design Verification Plan Establish a DVP to ensure product design meets specified requirements through
(DVP) testing and analysis (IATF 16949 clause 8.4.3)
2. Product
Conduct regular design reviews involving cross-functional teams to assess design
Design and Design Review
progress and compliance (IATF 16949 clause 8.3.2)
Development
Engineering Change Document and control engineering changes to ensure traceability and prevent
Document unintended consequences (IATF 16949 clause 7.5.1.1)
Develop a plan for product validation activities, including prototype testing and
Product Validation Plan
customer approval (IATF 16949 clause 8.4.4)
Complete PFMEA for manufacturing processes to identify potential failure modes
Process FMEA
and implement preventive measures (IATF 16949 clause 8.4.5)
Develop detailed process flow diagrams to define process steps, inputs, outputs,
Process Flow Diagram (PFD)
and controls (IATF 16949 clause 8.3.1)
3. Process Design
Develop process control plans to ensure consistent quality and compliance with
and Control Plan
customer requirements (IATF 16949 clause 8.5.1)
Development
Establish work instructions for operators to ensure standardized processes and
Work Instructions
reduce variation (IATF 16949 clause 7.5.1.1)
Develop a plan for process validation activities, including capability studies and
Process Validation Plan
production trials (IATF 16949 clause 8.5.1)
Complete PPAP submission to demonstrate product and process capability,
Production Part Approval
including documentation of measurement system analysis, control plans, and
Process (PPAP)
samples (PPAP 4th edition)
Measurement System Perform MSA to assess the adequacy and stability of measurement systems used for
4. Product and Analysis (MSA) product and process validation (IATF 16949 clause 7.1.5.1)
Process
Validation Implement production control plans to ensure consistent product quality and
Production Control Plan
compliance with customer requirements (IATF 16949 clause 8.5.1)

Conduct run-at-rate studies to verify production readiness and capability prior to

Run at Rate
full production launch (IATF 16949 clause 8.5.1.1)
Establish a process for identifying, documenting, and implementing corrective
Corrective Action Report
actions to address nonconformities and prevent recurrence (IATF 16949 clause
(CAR)
10.2.1)
Capture lessons learned throughout the APQP process and use them to drive
5. Feedback, Lessons Learned
continuous improvement (IATF 16949 clause 10.3)
Assessment, and
Corrective Action Warranty Data Analysis Analyze warranty data to identify trends, root causes, and opportunities for
preventive action (IATF 16949 clause 9.1.1)

Continuous Improvement Develop and implement a continuous improvement plan based on data analysis,
Plan customer feedback, and process performance metrics (IATF 16949 clause 10.3)